Device for converting carbonaceous matter into synthesis gas and associated methods

Abstract

A device for converting carbonaceous matter into synthesis gas includes a plasma head and a reformer connected to and extending downwardly from the plasma head. The plasma head may include a vortex zone, a plasma zone positioned beneath the vortex zone, and an oxidant input adjacent an upper portion of the vortex zone for inputting oxidant into the vortex zone. The plasma head may also include a high voltage electrode positioned to extend through a medial portion of the vortex zone and having a termination in the vortex zone so that high voltage discharge strikes are emitted into a lower portion of the vortex zone, a carbonaceous matter input for inputting carbonaceous matter into the plasma zone, and a plasma zone exit. The reformer may include a post plasma zone positioned beneath the plasma zone, a thermal barrier protective layer adjacent an uppermost portion of the post plasma zone adjacent an exit of the plasma zone, a catalyst carried by the post plasma zone, and a synthesis gas output.

1 . A device for converting carbonaceous matter into synthesis gas, the device comprising:
 a plasma head; and   a reformer connected to and extending downwardly from said plasma head;   wherein said plasma head comprises
 a vortex zone, 
 a plasma zone positioned beneath the vortex zone, 
 an oxidant input adjacent an upper portion of the vortex zone for inputting oxidant into the vortex zone, 
 a high voltage electrode positioned to extend through a medial portion of the vortex zone and having a termination in the vortex zone so that high voltage discharge strikes are emitted into a lower portion of the vortex zone, 
 a carbonaceous matter input for inputting carbonaceous matter into the plasma zone, and 
 a plasma zone exit, and 
   wherein said reformer comprises
 a post plasma zone positioned beneath the plasma zone of said plasma head, 
 a thermal barrier protective layer adjacent an uppermost portion of the post plasma zone adjacent an exit of the plasma zone, 
 a catalyst carried by the post plasma zone, and 
 a synthesis gas output. 
   
     
     
         2 . A device according to  claim 1  further wherein the reformer is housed by a double walled chamber having an entrance adjacent a lower portion thereof and an exit adjacent an upper portion thereof; and wherein the oxidant is inputted into the double walled chamber through the entrance at a first temperature, heated in the double walled chamber, and outputted through the exit at a second temperature. 
     
     
         3 . A device according to  claim 1  wherein the carbonaceous matter is glycerol. 
     
     
         4 . A device according to  claim 2  wherein the oxidant is inputted into the entrance of the double walled chamber at ambient temperature; wherein the oxidant is heated to a temperature between about 250° C. and 350° C. within the double walled chamber; and wherein the oxidant is inputted into the oxidant input on the plasma head at a temperature slightly lower than the output temperature from the double walled chamber of the reformer. 
     
     
         5 . A device according to  claim 1  wherein the high voltage discharge strikes are gliding and rotating high voltage discharge strikes. 
     
     
         6 . A device according to  claim 1  wherein the carbonaceous matter is reacted with the high voltage discharge strikes to produce a partial reformed product. 
     
     
         7 . A device according to  claim 6  wherein the plasma head further comprises an exit; wherein the partial reformed product exits the plasma head through the exit; and wherein the partial reformed product is reacted with the catalyst to form synthesis gas. 
     
     
         8 . A device according to  claim 1  further comprising a plurality of temperature sensors adapted to monitor temperatures throughout the post plasma zone and the reformer. 
     
     
         9 . A device according to  claim 1  wherein the plasma head further comprises a baffle adjacent the oxidant input; and wherein said baffle has a predetermined angle to cause torodial motion of the oxidant in the vortex zone. 
     
     
         10 . A device according to  claim 1  wherein said plasma head further comprises a metallic nozzle surrounding a medial portion of the electrode. 
     
     
         11 . A device according to  claim 10  wherein interior portions of the metallic nozzle are defined by an hourglass shape; and wherein the electrode is offset from an imaginary concentric line through the hourglass shaped interior portion of the metallic nozzle. 
     
     
         12 . A device according to  claim 1  further comprising a carbonaceous matter metering pump for metering and controlling a flow rate of carbonaceous matter inputted into the carbonaceous matter input. 
     
     
         13 . A device according to  claim 10  further comprising an insulator positioned to surround the high voltage electrode adjacent medial portions thereof and terminating so that a lower portion of the electrode is exposed adjacent the metallic nozzle in the vortex zone. 
     
     
         14 . A device according to  claim 1  further comprising a viscosity meter for metering viscosity of the carbonaceous matter; and wherein the viscosity meter comprises a processor to determine viscosity of the carbonaceous matter and adjust the viscosity of the carbonaceous matter to a predetermined viscosity prior to input of the carbonaceous matter into the carbonaceous matter input. 
     
     
         15 . A device according to  claim 1  wherein the thermal barrier protective layer is provided by nickel. 
     
     
         16 . A device according to  claim 1  wherein the temperature adjacent the plasma zone exit is between about 900° C. and 1250° C. 
     
     
         17 . A device according to  claim 1  wherein the high voltage electrode emits a voltage discharge between about 6 and 25 kV. 
     
     
         18 . A method for converting carbonaceous matter into synthesis gas, the method comprising the steps of:
 preheating an oxidant to a predetermined temperature;   inputting the preheated oxidant into a vortex zone;   exposing carbonaceous matter to the preheated oxidant;   reacting the carbonaceous matter that has been exposed to the preheated oxidant to high voltage discharge strikes emitted from an electrode to produce a partial reformed product in a plasma zone; and   reacting the partial reformed product with a catalyst to form synthesis gas in a post plasma zone.   
     
     
         19 . A method according to  claim 18  wherein the carbonaceous matter is glycerol. 
     
     
         20 . A method according to  claim 18  wherein the oxidant is preheated to a temperature between about 250° C. and 350° C. and wherein the oxidant is inputted into the vortex zone at a temperature slightly lower than the preheated temperature. 
     
     
         21 . A method according to  claim 18  wherein the high voltage discharge strikes are gliding and rotating high voltage discharge strikes. 
     
     
         22 . A method according to  claim 18  further comprising monitoring a temperature within the post plasma zone. 
     
     
         23 . A method according to  claim 18  wherein the oxidant is introduced into the vortex zone by passing it over a baffle to cause torodial motion of the oxidant in the vortex zone. 
     
     
         24 . A method according to  claim 18  further comprising metering and controlling a flow rate of the carbonaceous matter being exposed to the preheated oxidant. 
     
     
         25 . A method according to  claim 18  further comprising metering viscosity of the carbonaceous matter, and adjust the viscosity of the carbonaceous matter to a predetermined viscosity prior to exposing the carbonaceous matter to the preheated oxidant. 
     
     
         26 . A method according to  claim 19  wherein the temperature adjacent the plasma zone exit is between about 900° C. and 1250° C. 
     
     
         27 . A method according to  claim 19  wherein the high voltage electrode emits a voltage between about 6 and 25 kV.